Dry ice sheet technology has evolved rapidly, making cheap dry ice sheet for shipping a go to solution for 2025 cold chain logistics. These thin carbon dioxide filled mats can maintain temperatures as low as –78.5 °C without creating meltwater, reducing spoilage and waste. With the global dry ice market projected to grow from USD 1.67 billion in 2025 to USD 2.79 billion by 2032, understanding how to use affordable dry ice sheets properly will help you ship frozen goods safely while controlling costs.
What makes cheap dry ice sheets ideal for frozen shipments? – explores temperature range, moisture control and flexibility
How do you choose and size dry ice sheets for different transit times? – uses weight per day rules and thickness guidelines
What safety and regulatory rules govern shipping dry ice sheets? – summarises labeling, ventilation and training requirementslocalhost
How do dry ice sheets compare with gel packs and phase change materials? – contrasts temperature bands, moisture risk and cost
What innovations and trends are shaping dry ice sheet logistics in 2025? – reviews CO₂ recycling, smart monitoring and market growth
Why are cheap dry ice sheets ideal for frozen shipments?
Cheap dry ice sheets keep cargo at ultra cold temperatures without leaks or bulky weight, making them indispensable for long distance frozen shipments. Each sheet contains compact dry ice cells enclosed in multi layer polymer film that prevent moisture exposure and maintain temperatures from –78.5 °C to –18 °C for 24–96 h. Because carbon dioxide sublimates directly into gas, there is no meltwater to damage packaging or products. Flexible sheets line box walls and fold around irregular shapes, allowing you to use smaller boxes and reduce shipping costs. Compared with gel packs, they provide colder temperatures and longer duration while eliminating the risk of soggy packaging.
Dry ice sheets function like a high tech thermal blanket. Gel packs melt at 0 °C and behave like a melting ice cube; dry ice sheets behave like a self contained freezer. As carbon dioxide sublimates, it absorbs heat and escapes gradually through the sheet’s venting layer, keeping goods frozen without condensation. This means your seafood, meat or biologics stay rock solid for days, and you don’t have to mop up puddles at delivery. Because the sheets are thin and rollable, they reduce volume, so you can ship more product per box and cut shipping charges. They’re reusable when reinforced with polymer coatings, which further lowers cost per trip.
How do dry ice sheets work?
Dry ice sheets achieve their long lasting cold through three engineered components:
| Cooling component | Function | Typical duration | What this means for you |
| CO₂ sublimation cells | Solid CO₂ absorbs heat and converts directly to gas | 48–96 h | Provides long lasting sub zero temperatures with no liquid residue |
| Polymer film layer | Multi layer polymer film prevents moisture exposure and controls gas release | Continuous | Protects products and labels from condensation while venting gas safely |
| Thermal cell design | Evenly spaced cells distribute cold across the load | 24–72 h | Uniform freezing reduces hot spots and spoilage |
These components work together like a precision engineered freezer. The CO₂ cells act as cold batteries, absorbing heat. The polymer film ensures gas escapes slowly rather than bursting. The cell layout spreads cold evenly so no corner thaws prematurely. With proper insulation, a single sheet can maintain below –18 °C for up to four days.
Practical tips and scenarios
Seafood exports: Line the walls of your cooler with dry ice sheets and place a thinner sheet on top to create a thermal “lid.” This method reduced spoilage by 37 % in a case study when shipping salmon and tuna across Alaska.
Vaccines and biologics: Wrap vials or tissue samples in a secondary barrier (e.g., a gel pack or phase change buffer) before placing dry ice sheets on top. This prevents freezing damage while meeting strict temperature ranges.
Frozen meal kits: For e commerce deliveries, choose 10 mm sheets for 48 hour transit and pair them with insulated liners to cut weight and improve unboxing.
Actual case: A seafood exporter in Alaska switched from bulky ice bricks to dry ice pack sheets and kept products below –18 °C for 72 hours while cutting spoilage by 37 %. The thinner sheets allowed smaller boxes and reduced shipping costs.
How to choose and size cheap dry ice sheets for shipping?
Selecting the right dry ice sheet involves matching product sensitivity, transit duration and box volume to the sheet’s thickness and weight. Ultra cold items like cell therapies or gene treatments need thicker (≥20 mm) sheets for 96 hour endurance, whereas frozen pizzas may only need a 10 mm sheet for a weekend journey. A simple rule of thumb is to plan 5–10 pounds (2.27–4.54 kg) of dry ice per 24 hours of transit and adjust based on ambient temperature and insulation.
Sizing a sheet is like packing a cooler for a picnic—you need enough cold to outlast the trip without overpacking. Consider your product’s safe temperature range first. Vaccines shipped at –70 °C need more dry ice than ice cream at –20 °C. Assess transit time: local deliveries under 24 hours may require a single 5 mm sheet, while international shipments over 72 hours benefit from layering multiple sheets or using thicker versions. Empty space accelerates sublimation, so choose sheets that fit snugly and fill voids with crumpled paper or foam. Evaluate environmental impact by selecting reusable polymer layers and recycling spent sheets.
Thickness vs performance: Which sheet do you need?
| Thickness (mm) | Cooling duration | Recommended use case | Business benefit |
| 5 mm | 24–36 h | Local frozen delivery or same day shipments | Lightweight and flexible, fits small boxes |
| 10 mm | 48–72 h | Medium haul shipments or weekend deliveries | Balanced weight and cooling; cost effective |
| 20 mm+ | ≥96 h | International or pharmaceutical logistics | Extended cold retention for ultra sensitive cargo |
Practical sizing tips
Use the 1:1 rule for long hauls: Match the weight of dry ice to the weight of your product for shipments over 48 hours; for shorter routes, half the weight is usually enough.
Layer for multi zone cargo: Combine thinner and thicker sheets to create temperature gradients. This protects mixed loads (e.g., –20 °C meals and –70 °C biologics) without overcooling sensitive items.
Minimize air space: Fill voids with crumpled paper or foam to slow sublimation; less air means steadier temperatures.
Test before scaling: Simulate your route with a data logger before shipping at scale. Adjust sheet thickness and quantity based on results.
Real world tip: Combining sheets of different thicknesses creates a multi zone cooling effect, stabilizing temperature gradients in mixed load cargo.
Safety and regulatory considerations for shipping dry ice sheets
Dry ice is classified as a Class 9 “miscellaneous” hazardous material and must be packaged, labeled and documented correctly. Shipments must allow gas venting and be strong enough to withstand handling. Air shipments are limited to 200 kg of dry ice per package; the package must display a hazard Class 9 label with “Dry Ice, UN 1845” and the net weight. Ground shipments may be less regulated, but you still need to vent containers, label packages and complete any required declarationslocalhost.
Dry ice releases carbon dioxide gas, which can build up enough pressure to rupture packaging if the gas cannot escape. You must ensure the packaging allows the release of gas by venting the container; for example, do not use steel drums or jerricans as outer packaging, and do not place dry ice within sealed plastic bagslocalhost. Use good quality fiberboard (corrugated cardboard), plastic or wooden boxes as the outer box. A layer of Styrofoam within a box works well as insulation but should not be sealed airtight. Polystyrene foam must not be used as an outer packaging unless preapproved by the carrierlocalhost. The top of the package should not be completely sealed, allowing gases to ventlocalhost.
Pace University’s dry ice fact sheet provides similar guidelines: packages must allow gas release; never seal dry ice in an airtight container such as a jar or plastic cooler; pack dry ice loosely in an insulated shipping package. The package must be strong enough to withstand transport and constructed to prevent loss of contents due to vibration or temperature changes. Plastic materials that become brittle at low temperatures should be avoided. The airbill must include “Dry ice, 9, UN1845, number of packages × net weight in kilograms”. The package should be marked with “Carbon dioxide, solid” or “Dry Ice,” the full name and address of the shipper and consignee, and the net quantity of dry ice. Label the outermost container with a Class 9 hazard label and place it on a vertical side.
How to label and document dry ice shipments
Proper labeling and documentation ensure compliance with regulations and protect handlers. According to the Mercury dry ice packaging guide, the following markings are required on the same surface of the package:
Proper shipping name: “Dry Ice” or “Carbon Dioxide Solid”.
UN number: UN 1845.
Net quantity of dry ice in kilograms.
Shipper and recipient information: the full name and address of both parties must be durably marked on the package or on the provided label.
The label must include a Class 9 hazard diamond; you must not write inside the diamond’s border. The amount of dry ice and the name and address of the shipper and recipient should be noted either on the box or in the spot provided on the label. FedEx’s 2025 Dry Ice Job Aid notes that all self adhesive labels must be affixed directly to the package and not placed in or on a plastic pouchlocalhost. The net quantity of dry ice per package should be listed in kilograms (1 kg = 2 lb)localhost. When using a paper airbill, check “Yes, Shipper’s Declaration Not Required” and write “UN 1845, Dry Ice, __ × __ kg” (number of packages × net quantity) on the shipping documentlocalhost.
Packaging and handling best practices
| Best practice | Description | Reference | Practical benefit |
| Ventilation | Use containers with vented lids or breathable film to allow CO₂ gas to escapelocalhost | Prevents pressure buildup and explosion; ensures safety for handlers | |
| Package integrity | Choose boxes strong enough to withstand vibration and temperature changes | Prevents spillage and protects products during transit | |
| Material selection | Avoid plastics that become brittle at low temperatures; use purpose built insulated boxes | Minimises risk of cracks and leaks | |
| Weight limits | Limit dry ice to 200 kg per package for air shipments | Ensures compliance with IATA and DOT regulations | |
| Label placement | Attach hazard labels and shipping names on a vertical side; do not write inside the hazard diamond | Makes labels visible to handlers and inspectors | |
| Protective gear | Wear insulated gloves and goggles to avoid frostbite and eye injury | Protects employees during packing and handling | |
| Training | HazMat employees must receive general awareness and function specific training within 90 days of hiring and every two years for air shipping | Ensures staff know regulations and emergency procedures |
Tip: Mail order food safety guidelines also advise writing “Contains Dry Ice” and “Keep Refrigerated” on the box, alerting the recipient, and shipping early in the week so packages don’t sit in a facility over the weekendfsis.usda.gov.
How do dry ice sheets compare with gel packs and phase change materials?
Dry ice pack sheets deliver the coldest temperatures and longest duration, but gel packs and phase change materials (PCMs) serve different temperature bands and regulatory profiles. Dry ice sheets maintain –78.5 °C to –18 °C with no moisture and are treated as hazardous. Gel packs hold 0 °C to +5 °C for 12–36 hours and are non hazardous. PCMs occupy the middle ground, offering stable temperatures around –20 °C or +5 °C without hazardous classification but at a higher cost.
Choosing between these coolants is like selecting clothing for different climates—you wouldn’t wear a parka to a picnic or shorts on a glacier. Gel packs resemble a light jacket; they’re perfect for chilling produce or dairy between 0 °C and +5 °C. They melt into water, which can create mess and mould risk. PCMs are like a versatile windbreaker; they’re engineered to hold specific temperatures (e.g., –20 °C, –8 °C, +2 °C), transitioning between solid and liquid to absorb heat. They’re often non hazardous and reusable, making them suitable for multi day shipping of fresh foods or pharmaceuticals. Dry ice sheets, in contrast, are the heavy duty parka: delivering ultra cold conditions for frozen goods, vaccines and cell therapies. They require more care (hazard labels and venting) but can outperform other coolants when deep freeze is essential.
Choosing the right solution
Temperature requirement: If your shipment must stay below –20 °C, dry ice sheets are the only passive solution. For 2–8 °C ranges, PCMs or gel packs suffice.
Shipment duration: Long journeys (over 72 hours) favour dry ice or high end PCMs; short hauls benefit from gel packs.
Regulatory complexity: Gel packs and many PCMs avoid hazardous declarations, simplifying paperwork. Dry ice demands labeling and weight limits but offers unrivalled cold power.
Budget and sustainability: Dry ice sheets can be cost effective due to reusability and no electricity use. PCMs often have higher upfront cost but can be reused hundreds of times. Gel packs are inexpensive but disposable.
| Cooling method | Temperature range | Moisture risk | Duration | Regulatory classification | Typical application |
| Dry ice sheet | –78.5 °C to –18 °C | None | 48–96 h | Hazardous (Class 9) | Frozen foods, vaccines, biologics |
| Gel pack | 0 °C to +5 °C | Medium | 12–36 h | Non hazardous | Fresh produce, dairy, meal kits |
| PCM | –20 °C to +5 °C (formulation) | Low | 24–72 h | Often non hazardous | Temperature controlled pharmaceuticals, specialty foods |
Tip: Dry ice sheets require vented containers and hazard labels, while gel packs do not. If regulatory simplicity and mild cooling are your priorities, gel packs or PCMs may be more appropriate.
2025 trends and innovations in dry ice sheet shipping
The logistics sector is evolving rapidly. In 2025, dry ice pack sheets benefit from sustainability initiatives, smart monitoring and hybrid systems.
Sustainability and CO₂ recycling: Logistics hubs now recycle sublimated CO₂ gas, reducing emissions and cutting operational costs. Companies are investing in on site dry ice production, producing dry ice from captured CO₂ to ensure availability and reduce supply chain dependence. These efforts help reduce CO₂ waste by 15 %.
Smart temperature monitoring: IoT data loggers integrate into dry ice shipments, providing real time visibility through cloud dashboards. Studies show that 72 % of shippers require digital monitoring in 2025. Sensors alert teams to temperature excursions, improving compliance and reducing waste.
Hybrid packaging solutions: Combining phase change materials with dry ice sheets stabilises temperature transitions during customs delays or multi zone shipping. Over 62 % of global pharma distributors have shifted to hybrid packaging.
Automation and robotics: Cold chain warehouses adopt automated storage and retrieval systems and robotic handling to reduce labour costs and maintain consistent temperature control. About 80 % of warehouses are not yet automated, indicating huge potential for growth.
AI and predictive analytics: Artificial intelligence optimises routes, forecasts demand and predicts equipment maintenance. AI helps mitigate risks by analysing historical and real time data, improving decision making and reducing costs.
Growth in pharmaceutical cold chain: Approximately 20 % of new drugs are gene and cell therapies requiring ultra cold conditions. The global pharmaceutical cold chain market is expected to reach USD 1,454 billion by 2029.
Expansion of fresh food logistics: The North American food cold chain market is projected to reach USD 86.67 billion by 2025, driven by rising demand for plant based products and meal kits.
Self healing gels and solar recharging units: New dry ice packs contain polymers that seal punctures automatically, and solar panels can extend cold duration by 40 % during transit. On site dry ice generators provide greater self sufficiency.
These trends show that cheap dry ice sheet for shipping is becoming smarter, greener and more integrated into digital supply chains. Adopting these innovations can reduce spoilage, improve regulatory compliance and support sustainability goals.
Frequently asked questions
Q1: How long do cheap dry ice sheets last?
Most dry ice sheets maintain sub zero temperatures for 48–96 hours, depending on thickness, insulation and ambient conditions. For short routes, 5 mm sheets can provide 24–36 hours of cooling.
Q2: Are dry ice sheets safe for air freight?
Yes. When properly packaged and vented, dry ice sheets comply with IATA regulations. Packages must include a Class 9 hazard label, UN 1845 marking and net weight. Total dry ice must not exceed 200 kg per package.
Q3: Can I reuse dry ice sheets?
Many modern sheets have reinforced polymer coatings and can be reused multiple times. Inspect for tears and ensure the CO₂ cells are recharged or rehydrated according to manufacturer instructions.
Q4: How should I store unused dry ice sheets?
Store sheets in sealed containers or freezers below –20 °C to prevent premature sublimation. Avoid exposing them to warm environments until ready for use.
Q5: What’s the difference between dry ice sheets and pellets or blocks?
Pellets and blocks provide bulk cooling but are bulky and harder to fit around products. Sheets conform to irregular shapes and distribute cold evenly, making them ideal for space constrained logistics.
Q6: How much dry ice should I use per shipment?
A common recommendation is 5–10 pounds (2.27–4.54 kg) per 24 hours of transit. Match dry ice weight to product weight for long journeys and adjust for ambient temperature.
Summary and recommendations
Cheap dry ice sheet technology offers a powerful and flexible solution for shipping frozen goods in 2025. The sheets maintain ultra low temperatures without producing meltwater and can keep products frozen for 48–96 hours depending on thickness. Proper sizing is critical: follow the 5–10 pound per day rule and choose the right thickness for your transit time and product sensitivity. Safety and compliance are paramount—vent your containers, limit dry ice weight to 200 kg per package and label packages with “Dry Ice, UN 1845” and net weightlocalhost. Gel packs and PCMs have their place but cannot match the ultra cold performance of dry ice sheets. Looking ahead, sustainability initiatives, IoT monitoring and hybrid systems will make dry ice sheet logistics smarter and greener.
Recommended actions
Assess your shipment profile: Identify the required temperature range and transit duration. For shipments below –20 °C or longer than 72 hours, dry ice sheets are ideal. For 2–8 °C ranges or short hauls, consider gel packs or PCMs.
Calculate dry ice needs: Use the rule of 5–10 pounds of dry ice per 24 hours and select sheet thickness accordingly.
Optimize packaging: Minimize empty space, layer sheets for multi zone cargo and choose reusable polymer layers to reduce waste. Ensure containers vent gas and are strong enough for transit.
Ensure compliance: Vent containers, label packages with UN 1845 and Class 9 hazard symbols, note net weight, and train staff on hazardous materials ruleslocalhost.
Leverage technology: Adopt IoT monitoring and explore hybrid PCM–dry ice solutions to reduce risk and enhance visibility.
By following these steps, you can safely and efficiently use cheap dry ice sheets for shipping, reduce spoilage and meet 2025 sustainability goals.
About Tempk
Tempk is a global leader in cold chain packaging solutions. We specialise in advanced dry ice pack sheets and reusable insulation systems, helping businesses transport vaccines, biologics and frozen foods safely and sustainably. Our products maintain ±0.5 °C precision at –78 °C and are designed for over 200 reuse cycles. We prioritise eco friendly materials, carbon neutral manufacturing and compliance with GDP, FDA and IATA standards. By partnering with Tempk, you gain access to customised sizing, smart monitoring technology and continuous innovation.
Next step: Contact Tempk for a free consultation or explore our interactive sizing tool to select the right cheap dry ice sheet for your shipments. Our experts will help you design a compliant packaging system and reduce your environmental footprint.
